Headlight Relay Problems

[chocker]

Hi,
I'm in the process of doing the headlight relay mod and I'm having some issues. When I connect the system up, the bulb automatically is on high beam. When I turn the ignition switch on, it goes to low beam and when I try to switch it to high beam with the light switch nothing happens. I looked at the connection carefully I believe and I can't find the problem. Any help would be greatly appreciated.

Thanks,
Mark

[Pat Conlon]

I think the problem just might be reflected in the title of this post...
Headlight Relay Problems... You do have 2 spst relays, right? One relay for the low and the other for the high.

To rule out the handlebar switch, does it work properly when you hook up the oem circuit to the light?

If so, then check the logic on your wires.

[chocker]

The switch was working fine right before the new setup.  I do have two relays setup as well.  Off what i see it is connected correctly but Since it isn't working properly then maybe there is a wrong connection that i am not able to find.

Mark

[FJ1100mjk]

Re-check your connections again. When I did the mod a couple of years ago, it didn't work right when I first turned it on. But upon closer inspection, one connection on one of the relays was wrong. I got it right thereafter and all was well.

As you know, there's a number of wires to keep track of, and it's easy to mix them up. Especially with the small terminal designations (numbers) on the bottom of the relays, and how crowded they are when everything is connected up to them. Persevere, and you'll get it.

Good luck.

[FJ1100mjk]

Here's some notes and markups from my headlight relay mod. I cannot vouch for tbeir accuracies, but maybe they'll be of some help to you.

Colors stated, are what I used for my work, they are not the OEM wire colors.

[chocker]

Thanks for the info and the diagrams. I do have the first one but I think it is a matter of wire color. All I have lying around is yellow and black wires. That's where it gets a little tricky.

Mark

[chocker]

Thanks for all the help but I have made the decision to go with the Easternbeaver relay system. I received it and it is simply amazing and well worth it. The relays are super slim and fit nicely in the fairing. The quality of the connections and all the wiring is great. I compared it to my rig and my setup was terrible. It's so easy to install. Just in case you're thinking that I am involved with the company, I'm not. I just really like the product.

Thanks again,
Mark

[FJ1100mjk]

Good to hear that you were able to get a headlight relay in place. Regardless, if it is an aftermarket kit, or not, this mod is worthwhile.

I have installed a headlight relay kit from Eastern Beaver on a non-FJ application in the past. Their kits are good quality, and straightforward to install. I have also bought a number of other items from  him, including a quality crimper, that is a must-have if you expect decent connections when doing your own homemade electrical cables and harnesses.